Refrigerated merchandising apparatus

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of application Ser. No. 10/757,777, filed Jan. 15, 2004, now U.S. Pat. No. 6,945,415, entitled “REFRIGERATED MERCHANDISING APPARATUS”; which is a divisional of application Ser. No. 10/334,854, filed Dec. 31, 2002, now U.S. Pat. No. 6,701,736, entitled “REFRIGERATED MERCHANDISING APPARATUS”.

BACKGROUND OF THE INVENTION

The present invention is directed to a display merchandiser, and more particularly, to an inexpensive, disposable refrigerated merchandising apparatus having improved cooling capabilities and very high load capacity shelves.

For many years now, manufacturers with temperature sensitive products, primarily food or other consumable products, have sought a means by which their merchandise may be displayed openly, yet maintained at a desired, lower than ambient temperature. One approach includes permanent refrigerated display merchandisers constructed mainly of metal. These permanent units utilize a refrigeration unit enclosed and secured within the base and a fan associated therewith to move the refrigerated air up and over the merchandise displayed therein. Generally, at least one ducted outlet adjacent the front opening of the permanent merchandisers are oriented to create an air curtain for the apparatus. Essentially, the air curtain is a column of air which descends from the upper outlet to the lower refrigeration unit intake in order to prevent the cold air from spilling out of the apparatus. Other outlets are provided for the discharge of the refrigerated air to cool the merchandise.

One disadvantage of these permanent-type apparatus is that they are very costly to use for manufacturers test marketing new products. The increased capital first associated with a test marketing campaign often prohibits the introduction of many products.

Refrigerated merchandising display apparatus have been introduced for the test marketing campaigns. Generally, these apparatus include a housing having a receptacle for receiving a cooling module which provides refrigerated air for the merchandise. One major disadvantage of the prior art designs is that the air flow is not tightly controlled. Another disadvantage is that the construction of the housing is substandard for extended test marketing use. The housing is commonly constructed of corrugated cardboard. Wax-coated corrugated cardboard was introduced to delay the effects of liquid spills within the housing. However, prior art merchandising apparatus of this design are inferior for extended use and cannot accommodate larger packages of the merchandise because the shelves cannot handle the high weight requirements.

Therefore, there exists a need in the prior art for a refrigerated merchandising apparatus having improved strength and air flow handling characteristics which is inexpensive and disposable, if desired.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may best be understood by reference to the following description taken in conjunction with the accompanying drawings, in the several figures at which like reference numerals identify like elements.

<figref idref="DRAWINGS">FIG. 1</figref> is an exploded perspective view of the refrigerated merchandiser in accordance with one embodiment of the present invention.

<figref idref="DRAWINGS">FIG. 2</figref> is a cross-sectional view of the refrigerated merchandiser of <figref idref="DRAWINGS">FIG. 1</figref> in accordance with one embodiment of the present invention.

<figref idref="DRAWINGS">FIG. 3</figref> is a top plan view of a shelf in accordance with one embodiment of the present invention.

<figref idref="DRAWINGS">FIG. 4</figref> is a front elevation view of the shelf of <figref idref="DRAWINGS">FIG. 3</figref> in accordance with one embodiment of the present invention.

<figref idref="DRAWINGS">FIG. 5</figref> is a cross-sectional view of the shelf of <figref idref="DRAWINGS">FIG. 3</figref> taken along line A—A of <figref idref="DRAWINGS">FIG. 3</figref>.

<figref idref="DRAWINGS">FIG. 6</figref> is a detailed view of a highlighted portion of the shelf of <figref idref="DRAWINGS">FIG. 5</figref> in accordance with one embodiment of the present invention.

<figref idref="DRAWINGS">FIGS. 7–10</figref> illustrate the sequential steps for constructing a shelf in accordance with one embodiment of the present invention. <figref idref="DRAWINGS">FIG. 7</figref> illustrates a pair of core components in accordance with one embodiment of the present invention. <figref idref="DRAWINGS">FIG. 8</figref> illustrates a length of corrugated cardboard covering the oriented core components. <figref idref="DRAWINGS">FIG. 9</figref> illustrates fastening opposed ends of the corrugated cardboard to the core components. <figref idref="DRAWINGS">FIG. 10</figref> illustrates the composite construction of the shelf in accordance with one embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The refrigerated merchandiser of the present invention includes a display case and a cooling module. The display case includes a plurality of walls defining a cavity and a receptacle. The cavity is defined by a back wall, a pair of opposed side walls, a front wall, a top wall and a bottom wall. And the receptacle is defined by the back wall, the side walls, the front wall and the bottom wall. The bottom wall separates the cavity from the receptacle and includes an opening for fluid communication between the receptacle and the cavity. The receptacle is configured to receive the cooling module.

A plurality of vertically spaced shelves are disposed in the cavity extending between the side walls and include a top surface, a bottom surface and a rear surface. A display zone is defined as a volume disposed above the top surface of each shelf for the display of merchandise. A back panel is disposed in the cavity adjacent the back wall and spaced therefrom contiguous with the rear surface to define a duct in fluid communication with the bottom wall opening. The back wall includes a plurality of elongated openings, each disposed in fluid communication with the duct and one of the display zones. A turbulence generating element is disposed in each display zone adjacent the elongated opening.

A cooling module output for refrigerated air is in fluid communication with the bottom wall opening such that the refrigerated air moves through the duct and the back panel openings into contact with the turbulence generating elements which generate non-laminar air flow thereby blanketing the merchandise before falling to a return path.

In one embodiment of the present invention, a shelf for use in the refrigerated merchandiser includes a pair of foam elements, each having opposing first sides and a pair of opposing second sides. A C-channel element is connected to each first side defining a pair of core components. A length of corrugated cardboard covers the core components.

<figref idref="DRAWINGS">FIG. 1</figref> is an exploded perspective view of a refrigerated merchandiser <b>10</b> of one embodiment of the present invention. The refrigerated merchandiser <b>10</b> includes a display case <b>20</b> and a cooling module <b>22</b>. The display case <b>20</b> includes a plurality of walls defining a cavity <b>24</b> and a receptacle (<b>26</b>, as best shown in <figref idref="DRAWINGS">FIG. 2</figref>). The cavity <b>24</b> is defined by a back wall <b>28</b>, a pair of opposed side walls <b>29</b>, <b>30</b> a front wall <b>32</b>, a top wall <b>34</b> and a bottom wall <b>36</b>. The receptacle <b>26</b>, as better seen in <figref idref="DRAWINGS">FIG. 2</figref>, is defined by the back wall <b>28</b>, the side walls <b>29</b>, <b>30</b>, the front wall <b>32</b> and the bottom wall <b>36</b> such that the bottom wall <b>36</b> separates the cavity <b>24</b> from the receptacle <b>26</b>. The bottom wall <b>36</b> further includes an opening <b>38</b> for fluid communication between the receptacle <b>26</b> and the cavity <b>24</b>. The receptacle <b>26</b> is configured to receive the cooling module <b>22</b>.

A plurality of vertically spaced shelves <b>40</b> are disposed in the cavity <b>24</b> extending between the side walls <b>29</b>, <b>30</b>. As best seen in <figref idref="DRAWINGS">FIG. 2</figref>, the shelves each include a top surface <b>42</b>, a bottom surface <b>44</b>, a front surface and a rear surface <b>46</b>.

A display zone <b>48</b> is defined as a volume disposed above the top surface <b>42</b> of each shelf <b>40</b> for the display of merchandise. Generally, the display zone <b>48</b> is defined as that volume above the top surface <b>42</b> of a shelf <b>40</b> and bounded at the top by an adjacent shelf <b>40</b> or top wall <b>34</b> and at the sides by the respective opposed side walls <b>29</b>, <b>30</b>. The front of the display zone <b>48</b> is unbounded and generally defined by the front surface of the shelf <b>40</b>. A back panel <b>50</b> defines a boundary of the rear of the display zone <b>48</b>.

The back panel <b>50</b> is disposed in the cavity <b>24</b> adjacent the back wall <b>28</b> and spaced therefrom contiguous with the rear surface <b>46</b> of each shelf <b>40</b> to define a duct <b>52</b> in fluid communication with the bottom wall opening <b>38</b>. The back panel <b>50</b>, as best seen in <figref idref="DRAWINGS">FIG. 2</figref>, includes a plurality of elongated openings <b>54</b> disposed in fluid communication with the duct <b>52</b> and each of the display zones <b>48</b>. A turbulence generating element <b>56</b> is disposed in each display zone <b>48</b> adjacent the elongated opening <b>54</b>.

A cooling module output for refrigerated air <b>58</b> is in fluid communication with the bottom wall opening <b>38</b> such that the refrigerated air, indicated by the arrows, moves through the duct <b>52</b>, through the back panel openings <b>54</b> and into contact with the turbulence generating elements <b>56</b> which generate non-laminar flow above the merchandise <b>60</b>. The refrigerated air flow is thereby slowed down so that the merchandise <b>60</b> is blanketed with refrigerated air before the air flow falls to a return path, generally indicated by arrow <b>62</b>.

In one embodiment of the present invention, the back wall <b>28</b>, side walls <b>29</b>, <b>30</b>, top wall <b>34</b> and shelves <b>40</b> have a composite construction. Preferably, the composite construction includes at least a foam element and corrugated cardboard elements.

The back wall <b>28</b>, sides walls <b>29</b>, <b>30</b> and top wall <b>34</b> preferably have a composite construction wherein the corrugated cardboard is connected to an exterior surface of the foam element. In another embodiment of the present invention, an additional corrugated cardboard element may be connected to an interior surface of the foam element. It is within the teachings of the present invention that the corrugated cardboard element referred to herein may also include any corrugated cardboard having a coating applied thereto to resist moisture. Such coating may be any suitable coating used in the art. For example, the coating may be a wax, plastic or any other suitable element.

Referring to <figref idref="DRAWINGS">FIG. 2</figref>, in one embodiment of the present invention, the foam element <b>64</b> of the back wall <b>28</b> does not extend below the bottom wall <b>36</b>. It is within the teachings of the present invention, however, that if additional strength is required, the foam element <b>64</b> may extend the full length of the cardboard element. The side walls <b>29</b>, <b>30</b> are also similarly constructed. The front wall <b>32</b> in this embodiment primarily includes a cardboard element and a smaller foam element <b>66</b> disposed contiguous with the bottom wall <b>36</b> to support the transparent panel <b>68</b>.

In this embodiment of the present invention, each back panel elongated opening <b>54</b> extends substantially between the side walls <b>29</b>, <b>30</b>. Further, each elongated opening <b>54</b> is disposed adjacent the top boundary of the display zone <b>48</b>. The turbulence generating elements <b>56</b>, in this embodiment, are disposed in the display zones <b>48</b> adjacent the elongated opening <b>54</b>.

At least one shelf <b>40</b> has the turbulence generating element <b>56</b> connected to the bottom surface <b>44</b> thereof. Preferably, a turbulence generating element <b>56</b> is connected to the bottom surface <b>41</b> of each shelf <b>40</b> other than a lower-most shelf. Further, the top wall <b>34</b> includes an inner surface <b>70</b> having the turbulence generating element <b>56</b> connected thereto. In one embodiment of the present invention, the turbulence generating elements <b>56</b> are generally vertically aligned.

In another embodiment of the present invention, the top wall <b>34</b> includes a second turbulence generating element <b>56</b> disposed on the inner surface <b>70</b> spaced from the first turbulence generating element <b>56</b> adjacent the front-boundary of the display zones.

It is within the teachings of the present invention that all other walls of the display case <b>20</b> may be constructed in a composite manner as described above. In one embodiment of the present invention, the bottom wall <b>36</b> is constructed of plywood or other suitable material.

In operation, the refrigerated merchandiser <b>10</b> is lowered into position over the cooling module <b>22</b> in the direction of arrow <b>72</b> such that the bottom wall <b>36</b> is supported by a top surface <b>74</b> of the cooling module <b>22</b>. The cooling module <b>22</b> is connected to a conventional power source such as an electrical wall outlet in order to activate operation of the cooling unit <b>22</b>. Air is drawn into the cooling portion <b>76</b> of the cooling module <b>22</b> through opening <b>78</b>. The cooling area <b>76</b> of the cooling module <b>22</b> is shown as a schematic representation as the structure and operation thereof are conventional in the art. After the air has been appropriately cooled, a fan <b>80</b> further redirects the air from the cooling module output through the bottom wall opening <b>38</b> into the duct <b>52</b> for distribution throughout the display case <b>20</b>.

The refrigerated air flow moves up the duct <b>52</b> and is discharged generally as laminar air flow through the elongated openings <b>54</b> into contact with the turbulence generating element <b>56</b> disposed adjacent the elongated opening <b>54</b> in the respective display zone <b>48</b>. The turbulence generating elements <b>56</b> disrupt the laminar flow of the air discharged from the elongated openings <b>54</b> such that the airflow tumbles across the merchandise <b>60</b> as shown by the arrows in <figref idref="DRAWINGS">FIG. 2</figref>. As a result, the refrigerated air flow is considerably slowed so that the merchandise may be blanketed with the refrigerated air before falling to a return path <b>62</b>.

The second turbulence generating element <b>56</b> disposed on the inner surface <b>70</b> of the top wall <b>34</b> aids in redirecting the air flow from the top shelf <b>40</b> in the direction of a return path <b>62</b>. The resulting downward air flow urges air exiting from lower display zones <b>48</b> to also enter the return path <b>62</b>. The transparent panel <b>68</b> helps retain the air flow within the display case <b>20</b> such that it may be recirculated as explained above.

Referring now to <figref idref="DRAWINGS">FIGS. 3–10</figref>, a shelf <b>40</b> in accordance with one embodiment of the present invention is shown and discussed. <figref idref="DRAWINGS">FIG. 3</figref> is a top plan view of the shelf <b>40</b> in accordance with one embodiment of the present invention. As better illustrated in <figref idref="DRAWINGS">FIG. 7</figref>, the shelf <b>40</b> includes a pair of foam elements <b>100</b> each having a pair of opposing first sides <b>102</b> and a pair of opposing second sides <b>104</b>. It will be apparent to those of skill in the art that the opposed first sides are generally referred to as the long sides of the foam elements <b>100</b> and the opposing second sides <b>104</b> are generally referred to as the short sides of the foam elements <b>100</b>. However, it is within the teachings of the present invention that the first sides are equal in the extent or longer than the second sides. The C-channel element <b>106</b> is connected to each first side thereby defining, in this embodiment, a pair of core components <b>108</b>.

As best shown in <figref idref="DRAWINGS">FIG. 8</figref>, a length of corrugated cardboard <b>110</b> covers the core components <b>108</b>. The length of corrugated cardboard <b>110</b> includes opposed ends <b>112</b>, <b>114</b> which overlap when covering the core components <b>108</b>, see <figref idref="DRAWINGS">FIGS. 9 and 10</figref>. Preferably, in one embodiment of the present invention, the overlapping opposed ends <b>112</b>, <b>114</b> are connected to the core components <b>108</b> by threaded fasteners <b>116</b>. It is within the teachings of the present invention that any other suitable fastening or connecting device, method or apparatus may be used. For example, rivets, pushpins, adhesives, two-part fasteners, hook-and-loop fasteners or any other suitable mechanism or method.

<figref idref="DRAWINGS">FIGS. 4</figref>, <b>5</b>, <b>9</b> and <b>10</b>, each illustrate various different views of the turbulence generating element <b>56</b> are formed in the length of corrugated cardboard <b>110</b> between the overlapping opposed ends <b>112</b>, <b>114</b>. It is within the teachings of the present invention that the turbulence generating elements <b>56</b> may be formed separately from the length of corrugated cardboard <b>110</b> and connected to the shelf <b>40</b> as desired.

<figref idref="DRAWINGS">FIG. 5</figref> is cross-sectional view of the shelf of <figref idref="DRAWINGS">FIG. 3</figref> taken along the line A—A illustrating the shelf <b>40</b> in accordance with one embodiment of the present invention. As better illustrated in the detailed view of the <figref idref="DRAWINGS">FIG. 6</figref>, the core components <b>108</b> are disposed such that the respective first sides abut one another. The adjacent C-channel elements <b>106</b>, which have been fitted to the first sides <b>102</b> of the foam elements <b>100</b> are disposed in an abutting back-to-back relationship. Preferably, the C-channel elements <b>106</b> snugly fit the first sides <b>102</b> of the foam elements <b>100</b> without the need for fastening devices or methods. However, it is within the teachings of the present invention that any suitable fastening device or method may be used as desired.

The method of constructing a very high load capacity yet lightweight shelf, in accordance with one embodiment of the present invention, for use in a refrigerated merchandiser includes the steps of: (1) providing a pair of elongated foam elements <b>100</b>, each having a pair of opposed first sides <b>102</b> and a pair of opposed second sides <b>104</b>; (2) attaching a C-shaped channel element <b>106</b> to each first side to define a pair of core components (see <figref idref="DRAWINGS">FIG. 7</figref>); (3) orienting the core components such that the core components abut along first sides thereof; (4) covering the abutting core components <b>108</b> with a length of corrugated cardboard <b>110</b> having opposed ends <b>112</b>, <b>114</b> such that one of the opposed ends <b>114</b> overlaps the other <b>112</b> (see <figref idref="DRAWINGS">FIG. 8</figref>); and (5) connecting the opposed ends <b>112</b>, <b>114</b> of the length of corrugated cardboard to the core components <b>108</b> such that the second sides <b>104</b> are uncovered (see <figref idref="DRAWINGS">FIGS. 9 and 10</figref>). It is within the teachings of the present invention that the step of covering the core components includes using threaded fasteners <b>116</b> or any other suitable fastening means.

The invention disclosed herein is not limited to the particularly details of the apparatus depicted and modifications and applications maybe contemplated. For example, the materials described herein maybe substituted with any other suitable or less expensive materials which are suitable for the intended use. For example, various structures and configurations maybe used for the compositely formed shelves of the present invention. Certain other changes may be made in the above described apparatus with allowed to bargain from the true spirit and still of the invention here involved. Is intended, therefore that the subject matter of the above depiction shall be interpreted as illustrated and not in a limiting sense.